Low temperature method of forming materials using one or more metal reactants and a halogen-containing reactant to form one or more reactive intermediates

A low temperature process for forming a powder comprising one or more metal compounds which comprises:

• (a) reacting fluidized particles of one or more metal reactants, comprising a fluidized bed first reaction zone in a reactor, with a halide-containing reactant to form one or more reactive intermediates;
• (b) passing said one or more reactive intermediates from said first reaction zone to a second reaction zone in said reactor spaced from said fluidized bed comprising said first reaction zone;
• and
• (c) contacting said one or more reactive intermediates in said second reaction zone with a third reactant introduced into said reactor at said second reaction zone and selected from the class consisting of a carbon-containing reactant, an oxygen-containing reactant, a nitrogen-containing reactant, and mixtures thereof to form said metal compound powder comprising respectively, one or more metal carbides, metal oxides, metal nitrides, or a mixture thereof.

A low temperature process for forming silicon nitride which comprises:

• (a) reacting fluidized silicon particles, comprising a fluidized bed first reaction zone in a reactor, with a halide-containing reactant to form one or more reactive intermediates in said first reaction zone;
• (b) passing said one or more reactive intermediates from said first reaction zone to a second reaction zone in said reactor spaced from said fluidized bed comprising said first reaction zone;
• and
• (c) contacting said one or more reactive intermediates in said second reaction zone with a nitrogen-containing reactant to form silicon nitride powder in said second reaction zone.